Motorcycle Kickstarter Ural is not just a mechanism for starting an engine, but a real legend of Soviet and Russian motorcycle manufacturing. Despite the advent of electric starters, many owners classic Urals (models M-62, M-63, M-66, M-67 and modern Gear-Up, Retro) continue to use kickstarter as their main or backup method of launching. Its simplicity and reliability make it indispensable in off-road conditions or when the battery is low.

However, even the most reliable mechanism requires attention. Over time gears wear out, springs break, and improper operation can lead to serious damage. In this article we will analyze the kickstarter device Ural, typical malfunctions, we will give step-by-step repair instructions and share setup tips. And if you are just planning to buy a motorcycle with a kickstarter, you will find out what to look for during inspection.

The design and principle of operation of the Ural motorcycle kickstarter

Kickstarter Ural - This is a mechanical unit that converts the muscular force of the driver’s leg into the rotational movement of the crankshaft. Unlike an electric starter, it does not rely on a battery and can operate in any conditions. Main components of the system:

  • 🔧 Kickstarter lever - an external pedal that the driver presses. On classic models it was made of steel, on modern ones it could be aluminum.
  • ⚙️ Drive gear — connected to the lever through the shaft, transmits force to the intermediate gear.
  • 🔄 Intermediate gear - provides the gear ratio necessary to rotate the crankshaft.
  • 🔗 Clutch mechanism (overrunning clutch) — prevents the lever from kicking back when starting the engine.
  • 🌀 Return spring — returns the lever to its original position after pressing.

The principle of operation is simple: when you press the lever, the force is transmitted through the gears to the crankshaft, turning it. Overrunning clutch (so-called "bendix") disconnects the kickstarter and the engine after starting, preventing damage to the mechanism. On motorcycles Ural with gearbox 4+1 (four forward gears + reverse) the kickstarter is integrated into the left engine cover and operates regardless of the gear engaged.

Fun fact: on early models Ural-M62 (1960s) kickstarter had manual drive with cable mechanism, but already with M-63 switched to a foot lever, which is still used today. Modern motorcycles Ural Gear-Up And Retro retain this design with minimal changes.

Typical Ural kickstarter malfunctions and their symptoms

Even with careful use, kickstarter Ural wears out over time. A malfunction can be recognized by the following signs:

Symptom Possible reason Severity
The lever falls without resistance The return spring is broken or the lever mounting pin has popped out ⚠️ Medium (requires disassembly)
Crunching or grinding noise when pressed Worn gear teeth or foreign particles 🚨 High (may lead to jamming)
The lever does not return to its original position Overrunning clutch jammed or spring deformed 🚨 High (risk of breakdown during forced startup)
Heavy lever movement Lack of lubrication, shaft corrosion or lever bending ⚠️ Medium (can be eliminated without replacing parts)
Lever kickback when starting Malfunction of the overrunning clutch ("Bendix") 🚨 Critical (fraught with injury)

The most dangerous failure is lever kickback. It occurs when the overrunning clutch does not disengage the kickstarter from the crankshaft after the engine starts. In this case, the lever can jerk back sharply, which often leads to leg injuries. If you notice that kickstarter Ural started to "give" upon startup - stop using immediately and disassemble the mechanism!

⚠️ Attention! Never try to kickstart your motorcycle if the lever does not return to its original position when pressed. This may lead to overrunning clutch failure and expensive engine repairs.
📊 How often do you use kickstarter in the Urals?
  • Only in emergencies
  • Regularly, instead of electric start
  • Only for warming up in winter
  • I don't use it at all

Step-by-step instructions for disassembling the Ural kickstarter

If you decide to repair the kickstarter yourself, start by disassembling it. You will need:

  • 🔧 Set of open-end and socket wrenches (dimensions 10, 12, 14, 17 mm).
  • 🔨 Hammer and wooden spacer (for carefully removing gears).
  • 🧴 Lubrication Litol-24 or CV joint-4.
  • 🧲 Magnet for fastening (so as not to lose small parts).

Sequence of actions:

  1. Remove the left engine cover, first draining the oil (if required). On models Ural Gear-Up the cover is attached to 6 bolts, on classical M-66 - on 4 bolts And 2 stiletto heels.

  2. Disconnect the kickstarter lever by removing the mounting pin. Be careful - under the lever there is return spring, which can shoot!

  3. Remove the retaining ring from the kickstarter shaft (pliers will be required). On some models, instead of a ring, it is used Grover washer.

  4. Carefully remove the drive gear from the shaft. If it is tight, use a puller or a wooden spacer with a hammer.

  5. Remove the intermediate gear and overrunning clutch. Inspect the teeth for wear or chips.

When disassembling, pay attention to the condition oil seals - if they leak oil, they need to be replaced. Also check kickstarter shaft for bending: even a slight deformation can lead to heavy lever travel.

Wear of teeth of drive and intermediate gears|

Condition of the overrunning clutch (is there any play or jamming) |

Recoil spring integrity|

Cleanliness and presence of lubricant on the shaft |

Condition of seals and O-rings -->

Repair and replacement of worn parts

After disassembly, we begin repairs. The most common problems and ways to solve them:

  • 🔄 Gear wear: if the teeth are worn more than 30% or are chipped, the gears must be replaced. On classic Urals fit parts from Dnieper (models MT-9, MT-10).
  • 🔗 Overrunning clutch malfunction: If the clutch rotates in both directions or sticks, it needs to be replaced. As a temporary solution, you can wash the parts in kerosene and lubricate them, but this does not guarantee long-term operation.
  • 🌀 Spring breakage: The return spring breaks due to metal fatigue. Replace only with an original one or an analogue with the same hardness.
  • 🛠️ Shaft bend: if the shaft is bent, it can be straightened using a press, but it is better to replace it - even a slight bend accelerates wear on the gears.

When assembling, pay special attention lubrication. All rubbing surfaces (shaft, gears, overrunning clutch) must be coated with a thin layer Litola-24 or specialized gear lubricant. Avoid excess lubricant - it can get on the friction surfaces of the overrunning clutch and cause slippage.

⚠️ Attention! When replacing the overrunning clutch ("Bendix") do not mix up the installation side! There is usually a mark (dot or arrow) on the clutch body that should look towards the engine. Incorrect installation will result in the lever kicking back!

If you are replacing gears, pay attention to their markings. For example, on Ural M-67 the drive gear has 24 teeth, and the intermediate one - 36 teeth. Installing parts with a different number of teeth will result in incorrect operation of the mechanism.

Setting up and adjusting the kickstarter after repair

After assembly, the kickstarter requires configuration. Main parameters to check:

  1. Lever travel: It should be smooth, without jamming. If the lever moves slowly, check the alignment of the shaft and gears.

  2. Lever return: After pressing, the lever should immediately return to its original position. If the return is slow, the spring is weakened or broken.

  3. Crankshaft engagement: When you press the lever, you should hear a characteristic click of the overrunning clutch. If there is no click, the clutch does not engage.

To adjust the free play of the lever:

  1. Loosen the locknut on the lever shaft.
  2. Adjust the position of the lever so that it does not touch other parts in its original position.
  3. Tighten the locknut and check the stroke.

On motorcycles Ural Gear-Up with electric starter The kickstarter may require additional configuration due to the combined mechanism. In this case, check whether the kickstarter lever is interfering with the starter's operation.

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After repairing the kickstarter, do the first 5–10 starts on neutral gear - this will allow you to evaluate the smooth movement of the lever without load on the engine.

Operating Tips: How to Extend the Life of a Kickstarter

To kickstarter Ural served for a long time, follow these recommendations:

  • 🛢️ Lubricate the mechanism regularly: every 5,000 km add lubricant through the grease nipple (if provided by the design).
  • 🚗 Do not press the lever all the way unless necessary.: Enough vigorous movement for 2/3 turn to start.
  • ❄️ In winter, avoid sudden pressure: When the oil is cold, the engine resistance is higher, which increases the load on the kickstarter.
  • 🔧 Check the lever fastening periodically: A loose pin may cause the spring to break.

If the motorcycle has been standing idle for a long time, before using the kickstarter for the first time, turn the crankshaft manually (by the flywheel or using a wrench on the 36mm nut) to distribute the oil throughout the engine. This will reduce the load on the starter.

On motorcycles with side trailer (For example, Ural with a stroller) the kickstarter experiences increased loads due to the increased mass. In this case, it is recommended to use it only for emergency starting, giving preference to the electric starter (if installed).

What to do if the kickstarter is stuck in the pressed position?

If the kickstarter lever Ural jammed and it does not return, do not try to start the engine under any circumstances! First, remove the left engine cover and manually return the lever to its original position after releasing the spring tension. Most often, the cause is a jammed overrunning clutch or a foreign object getting between the gears. If the coupling is damaged, it will have to be replaced.

Where to buy spare parts for the Ural kickstarter and how much it costs

Kickstarter parts Ural can be purchased at the following places:

Detail Cost (RUB) Where to buy Analogues
Drive gear 800–1 200 Official dealers Ural, Avito, Drom.ru Gear from Dnepr MT-9
Overrunning clutch (Bendix) 1 500–2 500 IMZ-Ural.com, spare parts stores for Soviet equipment coupling from IZh Planeta-5 (with modification)
Return spring 300–500 Wildberries, Ozon, motor disassembly Spring from Ural M-66 (interchangeable)
Kickstarter shaft 2 000–3 500 Specialized online stores, for example MotoDetali.ru Shaft from Dnepr MT-10 (adjustment required)
Seal kit 400–700 Any spare parts store for domestic motorcycles Oil seals 25×42×7 mm (by size)

When purchasing spare parts, pay attention to metal quality. Cheap Chinese analogues are often made of soft alloys and fail due to 1,000–2,000 km. Original parts from Irbit Motorcycle Plant (IMZ) last many times longer.

If you are not sure about the choice, order parts at VIN code motorcycle - this guarantees compatibility. On classic Urals (up to 2000s) The VIN is stamped on the frame under the steering wheel, on modern models - on a special plate on the steering column.

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The most vulnerable part of a kickstarter Ural — overrunning clutch ("Bendix"). It fails more often than others and cannot be repaired, only replaced. Always keep a new clutch in stock, especially if you are planning long trips.

Frequently asked questions about the Ural Kickstarter

Is it possible to start the Ural with a kickstarter in gear?

Technically yes, but it is highly discouraged. Starting in gear places additional stress on the kickstarter and transmission. If the motorcycle is in gear, before starting with the kickstarter be sure to depress the clutch - this will reduce the load. However, it is always best to start in neutral.

Why does the Ural kickstarter sometimes “shoot” backwards?

Lever kickback occurs due to malfunction overrunning clutch. It should disconnect the kickstarter and crankshaft after the engine starts. If the clutch is worn or installed incorrectly, it will not block reverse rotation and the lever will jerk back. This is dangerous for the leg and can lead to mechanism failure. The solution is to replace the coupling.

What is the best lubricant to lubricate a kickstarter?

For kickstarter Ural Suitable high temperature lubricants:

  • Litol-24 - a classic, time-tested option.
  • CV joint-4 - a more modern alternative that can withstand high loads.
  • Castrol LMX — imported analogue, suitable for extreme conditions.

Do not use solid oil or graphite lubricant - they do not withstand loads and dry out quickly.

Is it possible to install a kickstarter from Dnepr to the Urals?

Yes, but with reservations. Kickstarters Ural And Dnieper (models MT-9, MT-10) are interchangeable in terms of fastenings, but may differ:

  • Lever length (at Dnieper it is sometimes shorter).
  • The number of teeth on the gears (you need to check compatibility).
  • Return spring stiffness.

Compare parts or consult a motorcycle technician before installation.

How long does the Ural kickstarter last on average?

Service life depends on operating conditions:

  • With careful use and regular maintenance - 50,000–80,000 km.
  • For intense off-road driving or frequent kickstarting - 20,000–30,000 km.
  • The overrunning clutch is usually the first to fail - its lifespan 15,000–25,000 km.

Helps extend the life of a kickstarter regular lubrication and avoiding sudden lever presses.